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Old 03-12-2017, 09:46 PM   #21
Waiex191
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1999 SL2
1998 SC2
Default Re: 96 SC2 bringing it back to life (slowly)

Hey Mark_b,
I've subscribed to your thread. In a month I am taking my 99 SL2 off the road for a rebuild with my 15 year old son. I am also doing this project for his benefit, it will be a great experience. Good luck with your project.

...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018

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Old 03-12-2017, 10:30 PM   #22
Mark_b
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1996 SC2
Default Re: 96 SC2 bringing it back to life (slowly)

@Saturn Night Thanks for the windows regulator setup info.

@Waiex191 My son will be 15 in June. I have really good memories rebuilding the motor for my first car. I hope this is a good learning experience for my son. I did not have anybody helping me that knew anything about cars but I did have books.
If you start a build post I would like to follow along. I hope your project is rewarding also.

Tractor supply had a sale. If spend $50 get $10 off so we now have paint, hardener and reducer. I also have parts washer solvent. I ended up doing two web orders and one in person so I saved $30.





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Old 03-15-2017, 04:43 PM   #23
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1996 SC2
Default Re: 96 SC2 bringing it back to life (slowly)

I bought a new power window motor for my driverís door Dorman 742-143 Window Lift Motor.

I was able to get a couple parts for my windows regulator from the JY. I just tested it outside the car and it worked well. So in need to clean it all up and lube it all up put it all back together.
Amazon had it on wherehouse deals special because it had a couple marks on it.
It was $23.18 I could care less it has a couple marks on it you donít see it at all.

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Old 03-15-2017, 05:20 PM   #24
Saturn Night
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1995 SC2
Default Re: 96 SC2 bringing it back to life (slowly)

And thankfully, it came with replacement bolts. I always wanted to find the engineers, that thought rivets were a great idea, and beat them senseless.

...
"What does a Saturn owner do, at the gas station?"

"He checks the gas, and fills the oil....."

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Old 03-26-2017, 08:51 AM   #25
Mark_b
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Default Re: 96 SC2 bringing it back to life (slowly)

We have the drives side window working. I used blue Loctite on the new bolts just incase.
This was the first time my son saw the window working. One thing down many to go.
http://www.youtube.com/watch?v=riolCfok9-Q

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Old 03-26-2017, 11:18 AM   #26
Saturn Night
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1995 SC2
Default Re: 96 SC2 bringing it back to life (slowly)

Looks good. Smooth operation, and the glass stayed nice and snug in its tracks. Should seal up fairly well, to resist water getting in.

...
"What does a Saturn owner do, at the gas station?"

"He checks the gas, and fills the oil....."

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Old 03-27-2017, 11:01 AM   #27
Mark_b
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Default Re: 96 SC2 bringing it back to life (slowly)

It works better than the passengerís window now. I will have to take off the right door panel and put new lube on the windows regulator. At least it works so that should be an easy job.

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Old 03-31-2017, 04:05 PM   #28
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Default Re: 96 SC2 bringing it back to life (slowly)

I put my 3D printer to work on my headlight motor. They are just small tabs the help keep the cover in place. I found the file to create these on the internet.
I put silicone on the cover to seal it up so it really should not need the tabs. But just in case they will keep the cover in place.
The motor is ready to go back in.

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Old 03-31-2017, 09:43 PM   #29
Saturn Night
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1995 SC2
Default Re: 96 SC2 bringing it back to life (slowly)

How exactly does a 3D printer work? Lasers?

You should try manufacturing various Saturn parts, with it. You could make a small fortune, with the input shaft nut......lololol

...
"What does a Saturn owner do, at the gas station?"

"He checks the gas, and fills the oil....."

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Old 04-03-2017, 01:07 PM   #30
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1996 SC2
Default Re: 96 SC2 bringing it back to life (slowly)

http://www.youtube.com/watch?v=H1KfNd4Z5sw
Here is a time-lapse video of a 3D printer like mine printing.

I put my headlight motor back in and it still does not work right. It will go up and down but the motor keeps running just like before.
I guess it stripped out my new gear right away.

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Old 04-03-2017, 01:38 PM   #31
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2002 SC2
1998 SL2
Default Re: 96 SC2 bringing it back to life (slowly)

possibly sensors (dirty contacts in the headlight control module)?
http://www.saturnfans.com/forums/showthread.php?t=65705

...
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11/2016 red 2002 5 spd SC2 124k DD
7/2010 Craigslist white 1997 SC2 project
12/2008 eBay silver 1998 SL2 5 spd 102k, now 201k+ miles

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Old 04-03-2017, 01:58 PM   #32
Mark_b
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Default Re: 96 SC2 bringing it back to life (slowly)

Thanks for the link.

Right now they will both go up and down but the passenger side motor keeps running.
Until I guess it times out. I looked at the top of the motor and after the motor goes up or down the great on top of the motor runs very fast until it times out.
I used supper lube in it maybe that stuff is too good for it.
I printed a new gear out of ABS I might still try this ABS gear.

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Old 04-03-2017, 02:18 PM   #33
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Default Re: 96 SC2 bringing it back to life (slowly)

From what I read control board will look for high current draw and turn off the motor.
So I guess either this motor is not drawing that much current or the control board is not sensing the high current draw.

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Old 04-07-2017, 06:37 PM   #34
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Default Re: 96 SC2 bringing it back to life (slowly)

The plastic gear I bought for the headlight motor did not work not even once. The ebay seller refunded me.
So I ordered a new brass CNC gear $26.


Here it is working. One more thing checked off the list.
http://youtu.be/Vjl_XDSIhIk
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Old 06-04-2017, 01:32 PM   #35
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Default Re: 96 SC2 bringing it back to life (slowly)

My new motor mounts came in.



My Son is out of school for the summer. He put together the engine stand and the parts washer.



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File Type: jpg 1496434240093.jpg (41.1 KB, 152 views)
File Type: jpg 20170602_145218.jpg (41.9 KB, 151 views)
File Type: jpg 20170603_141709.jpg (33.8 KB, 152 views)

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Old 08-01-2017, 03:13 PM   #36
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Default Re: 96 SC2 bringing it back to life (slowly)

I finally have my garage cleaned out enough to put the car in the garage. My son cleaned up the new valve cover and the timing cover. We have started taking things apart.







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File Type: jpg 20170730_192907.jpg (70.7 KB, 129 views)
File Type: jpg WP_20170729_001.jpg (54.6 KB, 129 views)
File Type: jpg WP_20170729_006.jpg (52.3 KB, 129 views)
File Type: jpg WP_20170715_010.jpg (51.0 KB, 129 views)
File Type: jpg WP_20170715_005.jpg (41.7 KB, 129 views)

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Old 08-04-2017, 10:35 PM   #37
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Default Re: 96 SC2 bringing it back to life (slowly)

We made some more progress. Headliner is out the sunroof is out. The sunroof motor is bad.

Now the car is in the air and we are getting everything undone to get the motor out.


Here is a picture of the sub frame it is hard to believe it is an 96 car.
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File Type: jpg 20170804_183906.jpg (57.8 KB, 117 views)
File Type: jpg 20170804_183924.jpg (46.3 KB, 120 views)

Last edited by Mark_b; 08-04-2017 at 10:41 PM..

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Old 08-07-2017, 12:14 PM   #38
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2002 SC2
1998 SL2
Default Re: 96 SC2 bringing it back to life (slowly)

Quote:
Originally Posted by Mark_b View Post

Here is a picture of the sub frame it is hard to believe it is an 96 car.
whenever I see such a picture, after the initial jealousy goes away then I have to check the poster's location. Yep, a state that doesn't salt their roads like a McDonald's fries
Even though that side tends to get an oil bath with each filter change, my cars still get a touch of rust here and there on the cradle

Very nice!

...
I'm not worthy to grovel in the shadow of Signmaster's wisdom

11/2016 red 2002 5 spd SC2 124k DD
7/2010 Craigslist white 1997 SC2 project
12/2008 eBay silver 1998 SL2 5 spd 102k, now 201k+ miles

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Old 08-08-2017, 08:04 PM   #39
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Default Re: 96 SC2 bringing it back to life (slowly)

Looks awesome!

...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018

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Old 08-13-2017, 08:33 PM   #40
Mark_b
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Default Re: 96 SC2 bringing it back to life (slowly)

I took a few more pictures of the undercarriage.





We only have a few more things to disconnect to pull the motor. We have not had much time to work on it but it is going well so far. My boy is learning some new skills. It is not always easy for me to step back but you learn by doing not watching.
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File Type: jpg 20170813_122652.jpg (45.3 KB, 98 views)
File Type: jpg 20170813_122618.jpg (22.8 KB, 98 views)
File Type: jpg 20170813_122606.jpg (28.9 KB, 98 views)
File Type: jpg 20170813_122634.jpg (53.6 KB, 98 views)

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